Valve monitor

ABSTRACT

A retrofittable valve monitor provides an input to an electrical circuit to indicate a fully closed position of a ball valve. A magnetically permeable object attached to the ball valve lever handle actuates a magnetic reed switch in a proximity sensor when the ball valve is moved to the fully closed position. A bracket which fits between the ball valve body and the ball valve lever handle is held in place by the ball valve locking nut so the proximity sensor is held in proper alignment to be actuated by the magnetically permeable object. The actuated reed switch provides an input to a switched electrical circuit.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates generally to the field of equipmentmonitoring, and more particularly, but not by way of limitation, to avalve monitor which is adaptable to monitor the fully open or fullyclosed position of a ball valve.

[0003] 2. Discussion

[0004] Ball valves are widely used in steam, water, oil, and gassystems. Some are of plastic (usually PVC) construction wherein aplastic internal port rotates between fully closed and fully open in aplastic valve body. Others are of heavy duty forged brass construction.A plated steel handle with vinyl grip is used to rotate a brass stem,which is attached to an internal port, through one-quarter of a turn,thereby moving the valve from fully open to fully closed position. BothPVC and brass ball valves are common in a variety of residential andindustrial applications.

[0005] In certain applications, for example, in wet or dry firesprinkler systems, it is desirable to have an electrical signalindicating whether the ball valve is in the fully open position. Oneprior art ball valve with supervisory switch uses two sets of SPDT (FormC) switches in a Nema 4 rated enclosure (when used with proper conduitfittings). The two sets of SPDT contacts operate when the valve positionis altered from an open state. The ball valve with supervisory switchdescribed hereinabove, which operates on 125/250 VAC, is not suitablefor use in hazardous locations and, furthermore, is relativelyexpensive. In addition, the prior art ball valve with supervisory switchis bulky, measuring (for a 1-inch valve) 4.8 inches long by 2.6 incheswide by 5.5 inches high.

[0006] Because of its size, the supervisory switch gear blocks access tothe ball valve when replacement is required. A two-step process tochange out the ball valve with supervisory switch involves, first,removal of the supervisory switch gear and, then, removal of the ballvalve from line in which the ball valve is installed.

[0007] Available valve monitors do not provide a cheap, compact, easilymanufactured, effective, retrofittable valve monitor which can be usedto monitor ball valves in both hazardous and non-hazardous applications.

SUMMARY OF THE INVENTION

[0008] The present invention provides a valve monitor to monitor thefully open or fully closed position of a ball valve. For a forged brassball valves having a steel lever handle with two tabs which come to restagainst a stop in either the full open or the full closed position, thevalve monitor provides a proximity sensor positioned to sense thepresence of magnetically permeable material—in this instance, one of thetabs on the valve lever handle. The proximity sensor consists of asealed magnetic reed switch axially disposed in a magnetic field nullposition in an applied magnetic field so that the magnetically permeablematerial, i.e., the steel tab on the valve lever handle, unbalances thebalanced magnetic field and actuates the magnetic reed switch. A bracketcontaining the proximity sensor in a cavity mounts directly on the bodyof the brass valve immediately under the valve lever handle.

[0009] The valve monitor's sealed magnetic reed switch is suitable foruse in a variety of environments, including hazardous environments. Thevalve monitor of the present invention is compact, measuringapproximately 1.75 inches wide by 0.75 inches thick by 2.375 incheslong. When attached to a standard 1-inch brass ball valve, the valvemonitor adds about 0.1 inch to the height, about 0.5 inches or less tothe diameter, and nothing to the length of the brass ball valve. Moreimportant, the valve monitor of the present invention providesunobstructed access to the ends of the ball valve for installation andremoval.

[0010] In another embodiment, the bracket houses only a magnetic reedswitch which is actuated by a small magnet attached to the valve leverhandle. This embodiment is suitable not only for brass valves havingsteel lever handles, but also for ball valves constructed of PVC andother types of plastic.

[0011] An object of the present invention is to provide an inexpensive,easily manufactured, and effective valve monitor for ball valves.

[0012] Another object of the present invention is to provide a valvemonitor which can be easily installed on existing ball valves.

[0013] Yet another object of the present invention is to provide a valvemonitor which is suitable for use in both hazardous and non-hazardousenvironments.

[0014] Yet another object of the present invention is to provide a valvemonitor which is compact in physical size.

[0015] Yet another object of the present invention is to provide acombination ball valve and valve monitor which can be easily installedor replaced in existing water, gas, oil, and steam lines.

[0016] Other objects, features, and advantages of the present inventionwill become clear from the following description of the preferredembodiment when read in conjunction with the accompanying drawings andappended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 is a pictorial view of a first embodiment of the valvemonitor installed on a ball valve.

[0018]FIG. 2 is a view, partially cut away, of the valve monitordepicted in FIG. 1.

[0019]FIG. 3 is a cross-sectional view of the valve monitor along 3 inFIG. 2.

[0020]FIG. 4 is a view, partially cut away, of the valve monitor ofFIGS. 1-3 modified to include a quick connector.

[0021]FIG. 5 is a view of the valve monitor of FIGS. 1-3 showing theorientation of a proximity sensor wherein the valve monitor provides aninput to an electrical circuit when the ball valve BV is in the fullyclosed position.

[0022]FIG. 6 is a view of another embodiment of the valve monitorshowing the orientation of a proximity sensor wherein the valve monitorprovides an input to an electrical circuit when the ball valve BV is inthe fully open position.

[0023]FIG. 7 is a view of another embodiment of the valve monitorwherein a magnet attached to the valve lever handle actuates a magneticreed switch to provide an input to an electrical circuit when the ballvalve BV is in the fully closed position.

[0024]FIG. 8 is a view of another embodiment of the valve monitorwherein the magnet is located at a different position on the valve leverhandle actuates and actuates a magnetic reed switch to provide an inputto the electrical circuit when the ball valve BV is in the fully openposition.

[0025]FIG. 9 is a view of a still more compact embodiment of the valvemonitor wherein a magnet is attached to the valve lever handle actuatesa magnetic reed switch to provide an input to an electrical circuit whenthe ball valve BV is in the fully closed position.

[0026]FIG. 10 is a view of another embodiment of a compact valve monitorwherein the magnet is located at a different position on the valve leverhandle and actuates a magnetic reed switch to provide an input to anelectrical circuit when the ball valve BV is in the fully open position.

DETAILED DESCRIPTION OF THE INVENTION

[0027] In the following description of the of the present invention,like numerals and characters designate like elements throughout thefigures of the drawings.

[0028] Referring generally to the drawings and more particularly toFIGS. 1-3, a valve monitor 20 is shown in conjunction with a forgedbrass ball valve BV. The forged brass ball valve BV includes a valvebody 22 having a valve collar 24 extending upwardly from thecircumference of the valve body 22 and a threaded valve stem 26 disposedwithin the valve collar 24. The valve collar 24 has a stop 28 integrallyforged therewith. A lever handle 30 mates with the threaded valve stem26 and is held in place by a self-locking nut 32.

[0029] Ball valves, generally, and forged brass ball valves, inparticular, are well known in the art and require a quarter turn of thevalve stem 16 to move an internal port (not shown) from a fully openposition to a fully closed position. The ball valve BV of FIG. 1 isshown in the fully open position. The lever handle 30 has tabs 34 and36. In the fully open position, tab 36 on the lever handle 30 is biasedagainst the stop 28 on the valve collar 24. The lever handle 30 is usedto rotate the valve stem 26 through a quarter turn clockwise so that thetab 34 is then biased against the stop 28 when the ball valve BV isfully closed.

[0030] Still referring to FIGS. 1-3, the valve monitor 20 is installedon the brass ball valve BV between the lever handle 30 and the valvecollar 24. The valve monitor 20 has an opening 38 and a slot 40extending outwardly from the opening 38. The opening 38 and the slot 40cooperate to receive the valve collar 24 and the stop 28 on the valvecollar 24 of the forged brass ball valve BV. The stop 28 on the valvecollar 24 serves as a key and the slot 40 as a keyway to maintain thevalve monitor 20 in mating position with the brass ball valve BV.

[0031] Still referring to FIGS. 1-3, a recess 42 permits the tabs 34, 36on the valve lever handle 30 to move freely from the fully open position(wherein tab 34 rests against the stop 28) to the fully closed position(wherein tab 36 rests against the stop 28). A contour 44 on the bottom46 of the valve monitor 20 mates with the valve body 22. A proximitysensor 48 (See FIGS. 3-5) is enclosed within a cavity 50 adjacent andgenerally perpendicular to the slot 40. In FIGS. 1 and 3, reed switchleads 52 connect the proximity sensor 48 to an electrical circuit (notshown).

[0032] Referring now to FIGS. 1 and 2, a slit 54 creates jaws 56 and 58.The jaw 56 has a counterbore 60, and a bore 62 in the jaw 58 (See FIG.2) is tapped to receive a screw 64. When the screw 62 is tightened inthe tapped jaw 58, the jaws 56, 58 are forced together at the slit 54and the opening 38 of the valve monitor 20 is forced against the valvecollar 24, thereby further securing and stabilizing the valve monitor 20between the valve lever handle 30 and the valve body 22.

[0033] Proximity sensors are known in the art. One such proximity sensoris the subject of U.S. Pat. No. 5,128,641. A magnetic reed switch isdisposed within the polarity neutral portion of a magnetic field. Anapproaching magnetically permeable object disturbs the magnetic fieldand actuates the magnetic reed switch. The approaching magneticallypermeable object may be ferrous metal or a magnet. The valve monitoraccording to the present invention adapts such a proximity sensor tomonitor the position of a ball valve BV.

[0034] In FIG. 2, a top view of the valve monitor 20 of FIG. 1 shows thetapped bore 62 in the jaw 58. In FIG. 3, potting compound 66 holds theproximity sensor 48 in place in the cavity 50.

[0035] Referring now to FIG. 4, the reed switch leads terminate at aconnector 68 for ease of connected of the valve monitor to the switchedelectrical circuit.

[0036] Referring now to FIG. 5, the proximity sensor 48 is deployedwithin the cavity 50 of the valve monitor 20. The proximity sensor 48includes a target area 68 positioned so as to be adjacent themagnetically permeable object—in this case the tab 34 on the valve leverhandle 30—which will actuate the magnetic reed switch of the proximitysensor 48 and provide an input signal to the electrical circuit when theball valve BV is in the fully closed position.

[0037] Referring now to FIG. 6, a valve monitor 80 according to thepresent invention provides an input to the electrical circuit when theball valve BV is in the fully open position. The proximity sensor 48 hasbeen flipped (vis-a-vis its orientation in FIG. 5) so that the targetarea 68 will be aligned with the tab 36 on the valve lever handle 30when the ball valve BV is in the fully open position.

[0038] Referring now to FIG. 7, a valve monitor 100 according to thepresent invention provides input to the switched circuit when the ballvalve BV is in the fully closed position. A reed switch 102 is deployedwithin the cavity 50 so that, as the ball valve BV is closed by movementof the lever handle 30, a magnet 104 attached to the tab 34 of the leverhandle 30 actuates the reed switch 102 and provides input to theswitched electrical circuit. The reed switch 102 depicted in FIG. 7 isclosed due to the presence of the magnet 104.

[0039] Referring now to FIG. 8, a valve monitor 120 according to thepresent invention provides input to the switched electrical circuit whenthe ball valve BV is in the fully open position. The reed switch 102 ispositioned within the cavity so that, as the ball valve BV is opened bymovement of the lever handle 30, a magnet 104 attached to the tab 36 ofthe lever handle 30 actuates the reed switch 102 and provides input tothe switched electrical circuit. As depicted in FIG. 8, the reed switch102 is open because the magnet 104 is not present to cause the reedswitch 102 to close.

[0040] Referring now to FIGS. 7-10, the cavity 50 in which the reedswitch 102 is deployed is filled with potting compound 66. The pottingcompound 66 stabilizes the position of the reed switch 102 within thecavity 50 and protects the reed switch 102 from damage.

[0041] It will be understood to one skilled in the art that the valvemonitors 100 and 120 according to the present invention are suited forapplications with ball valves made from any material except ferrousmetal. By way of illustration, the reed switch 102 could be positionedso as to be actuated by a magnet 104 attached to the lever handle of aplastic ball valve.

[0042] It will be further understood to one skilled in the art that thevalve monitors 100 and 120 according to the present invention aresmaller than the valve monitors 20 and 80 because the larger proximitysensor 48 has been replaced by the much smaller reed switch 102 actuatedby the magnet 104.

[0043] Referring again to FIGS. 7-10, it will be further understood byone skilled in the art that the leads 52 attaching the magnetic reedswitch 102 to the switched electrical circuit can be arranged as desiredwithin the cavity 50.

[0044] Referring now to FIGS. 9 and 10, shown therein are valve monitors140 and 160. Generally, valve monitors 140 and 160 operate in the samemanner as the valve monitors 100 and 120 of FIGS. 7 and 8, respectively.The valve monitors 140 and 160 are still more compact, however, due toelimination of the counterbore 60 in the jaw 56, the bore 62 in the jaw58, and the screw 64. The valve monitors 140 and 160 are held betweenthe valve lever handle 30 and the valve body 22 by the self-locking nut32.

[0045] While applicants' invention is illustrated herein as being anormally open magnetic reed switch, it will be understood to one skilledin the art that reed switches can be either normally open or normallyclosed. A single-pole, single-throw (SPST), normally-open magnetic reedswitch (also referred to by those skilled in the art as a Form “A” reedswitch) is illustrated herein. Single-pole, single-throw (SPST),normally-closed magnetic reed switches (also referred to by thoseskilled in the art as Form “B” reed switches) are known in the art andsuitable for use in applicants' valve monitor.

[0046] Referring now to FIG. 1, a proximity sensor utilizing a Form Areed switch will close when the ball valve BV is in the fully closedposition. A proximity sensor utilizing a Form B reed switch will remainclosed unless the ball valve BV is in the fully closed position.

[0047] The foregoing descriptions of specific embodiments of the presentinvention have been presented for purposes of illustration anddescription. They are not intended to be exhaustive or to limit theinvention to the precise forms disclosed, and obviously manymodifications and variations are possible in light of the aboveteaching. The embodiments were chosen and described in order to bestexplain the principles of the invention and its practical application,to thereby enable others skilled in the art to best utilize theinvention and various embodiments with various modifications as aresuited to the particular use contemplated. It is intended that the scopeof the invention be defined by the claims appended hereto and theirequivalents.

We claim:
 1. A valve monitor for monitoring the position of a ballvalve, the ball valve being characterized as having a valve body with anupwardly extending valve collar, the valve collar having an internalport which moves a quarter turn between a fully open position and afully closed position, a valve stem attached to the internal port, and avalve lever handle attached to the valve stem, so that movement of thevalve lever handle turns moves the ball valve from the fully openposition to the fully open position, said valve monitor comprising: amagnetically permeable object attached to the valve lever handle; aproximity sensor positioned adjacent the valve collar so that saidmagnetically permeable object actuates the proximity sensor when theball valve is moved to the fully closed position; and mounting means formounting said proximity sensor on the valve body in operationalalignment with said magnetically permeable object.
 2. The valve monitorof claim 1, wherein said magnetically permeable object is a ferrousmetal tab on the valve lever handle, so that said ferrous metal tabactuates said proximity sensor when the valve lever handle moves theball valve to the fully closed position.